Solid-fuel rocket propellants comprising an oxidizer, an oxophilic metal-halophilic metal formulation, and a binder are described herein. Further described are processes for preparing such propellants and methods of reducing hydrogen chloride production via the combustion of such propellants. Non-limiting examples of such formulations include aluminum-lithium alloys.

Solid-fuel rocket propellants comprising an oxidizer, an oxophilic metal-halophilic metal formulation, and a binder are described herein. Further described are processes for preparing such propellants and methods of reducing hydrogen chloride production via the combustion of such propellants. Non-limiting examples of such formulations include aluminum-lithium alloys.

A hybrid rocket motor includes a solid fuel element, and an oxidizer tank containing an oxidizer. The solid fuel element adjoins and at least partially defines a combustion chamber in which the solid fuel and the oxidizer are burned, to produce thrust from the hybrid rocket motor. The oxidizer tank is at least partially within the combustion chamber, and the entire oxidizer tank may be within the combustion chamber. The oxidizer tank may be protected by an insulating material, which may also serve as a structural material that contains the pressure of the oxidizer. The insulating material and the fuel material may both be polymer-based materials, although they may be different materials having different characteristics, for example including different additives to the same polymer material. The fuel element and the oxidizer tank may be made by additive manufacturing processes, for example by adding different materials in different locations.

An additively manufactured solid fuel grain for a hybrid rocket engine having a cylindrical shape, defining a center combustion port and comprising a stack of fused layers of polymeric material suitable for hybrid rocket fuel. Each layer is formed as a plurality of fused abutting concentric beads of solidified material arrayed around the center port. An oxidizer is introduced into the solid fuel grain through the center port, with combustion occurring along the exposed surface area of the solid fuel grain center port wall. Each concentric bead possesses a surface pattern that increases the combustion surface area and when stacked forms a rifling pattern of undulations that induces oxidizer-fuel gas axial flow to improve combustion efficiency. The port wall surface pattern persists during the rocket engine's operation as the fuel phase changes from solid to gas and is ablated.

A rocket booster has an annular shape, with a casing defining an annular space therewithin, and a solid rocket fuel in the annular spacing. The casing may itself at least in part define an annular gap that functions as a nozzle for the rocket booster, with protruding tabs on the casing aiding in maintaining a uniform height of the annular gap. The rocket booster may be mechanically coupled to an object protruding from the back of a fuselage of a flight vehicle, such as a missile. For example, the rocket booster may be placed around an aft turbojet nozzle of the flight vehicle. This allows the rocket booster to be used in situations where primary propulsion must be running both before and after (and perhaps during) the firing of the rocket booster.

A rocket booster has an annular shape, with a casing defining an annular space therewithin, and a solid rocket fuel in the annular spacing. The rocket booster also includes one or more nozzle pieces, mechanically coupled to the casing, that define one or more nozzles at the aft side of the rocket booster. The rocket booster may be mechanically coupled to an object protruding from the back of a fuselage of a flight vehicle, such as a missile. For example, the rocket booster may be placed around an aft turbojet nozzle of the flight vehicle. This allows the rocket booster to be used in situations where primary propulsion must be running both before and after (and perhaps during) the firing of the rocket booster.

A method of producing a propellant material element, such as an electrically-operated propellant material, includes extruding a propellant material through a heated nozzle. The nozzle may be heated to a temperature that is above the boiling point of a solvent that is part of the propellant material, yet is below a decomposition temperature of the propellant material. This allows some of the solvent to be driven off during the extruding process, while still preventing initiation of an energy-creating reaction within the material. The heating of the material in the extruding process, and especially the heating of the nozzle that the material is extruded through, may be controlled to remove an amount of solvent that results in the extruded material having desirable properties.

A propellant manufacturing method for manufacturing a propellant including a propellant grain having a first surface on which combustion starts upon ignition and a second surface to be coupled to a wall surface that prevents combustion. The manufacturing method includes placing a portion of first propellant having a first burning rate in a first space containing a first position on the second surface; and placing a portion of second propellant having a second burning rate higher than the first burning rate in a second space containing a second position on the first propellant. The method further includes placing a portion of third propellant having a third burning rate higher than the second burning rate in a third space containing a third position on the first propellant. The method further includes completing the propellant grain by simultaneously hardening the entireties of the first propellant, the second propellant, and the third propellant.

A propellant manufacturing method for manufacturing a propellant including a propellant grain having a first surface on which combustion starts upon ignition and a second surface to be coupled to a wall surface that prevents combustion. The manufacturing method includes placing a portion of first propellant having a first burning rate in a first space containing a first position on the second surface; and placing a portion of second propellant having a second burning rate higher than the first burning rate in a second space containing a second position on the first propellant. The method further includes placing a portion of third propellant having a third burning rate higher than the second burning rate in a third space containing a third position on the first propellant. The method further includes completing the propellant grain by simultaneously hardening the entireties of the first propellant, the second propellant, and the third propellant.

A process for removing webs formed on a wall of a central channel of a propellant charge, the process including removing webs by levelling the wall of the central channel of the propellant charge with a levelling tool installed on an articulated robotic arm during which the movements of the robot arm are controlled by a user interface which includes a controller configured to be used by a user; a force sensor measures the force applied by the levelling tool; a control unit connected to the force sensor regulates the movements of the robot arm by maintaining the force applied by the levelling tool below a first predetermined force threshold, the control unit also regulating the movements of the robot arm by maintaining a movement speed of the levelling tool which is below a predetermined speed threshold value.